Rearview mirror assembly

ABSTRACT

The subject invention is a bracketless rearview mirror assembly ( 10 ) that is inexpensive and provides an easy assembly technique to attach the mirror assembly to a side of a motor vehicle ( 12 ). The mirror assembly includes a case ( 14 ) with a reflective mirror ( 16 ) and a guide mechanism ( 26 ). The motor vehicle ( 12 ) includes a mounting surface ( 48 ) with an opening ( 52 ) disposed between an inner side ( 48 ) and an outer side ( 50 ). A connector ( 42 ) is positioned between the case ( 14 ) and the inner side ( 48 ) of the mounting surface ( 46 ) of the vehicle. An adjustment mechanism ( 20 ) extends from inside the case, through the guide mechanism ( 26 ) and the connector ( 42 ), to the inner side ( 48 ) of the mounting surface ( 46 ). The adjustment mechanism ( 20 ) can be a simple handle ( 68 ) for manual adjustment or a harness ( 84 ) for encapsulating electronic controls for electrically adjusted mirrors. The mirror assembly ( 10 ) also allows the case ( 14 ) to move about the guide mechanism ( 26 ) and adjustment mechanism ( 20 ) to fold inward toward the vehicle ( 12 ).

TECHNICAL FIELD

The present invention relates to a rearview mirror assembly with abracketless mounting feature for attaching the mirror assembly to a sideof a vehicle, and, more particularly, the present invention relates to arearview mirror assembly with a mounting feature adaptable for variousadjustment mechanisms.

BACKGROUND OF THE INVENTION

Traditional side rearview mirror assemblies are expensive and difficultto assembly in a mass-manufacturing environment. They require a mountingbracket that attaches a housing of the mirror assembly to a side of amotor vehicle. This bracket adds to the overall cost of the mirrorassembly. Additionally, the design of the bracket becomes specific toone particular vehicle since it is an exterior trim piece and mustcooperate with the overall design scheme of the vehicle. Creatingdifferent brackets for different vehicles also adds to the cost of themirror assembly.

In addition to the bracket having a specific design for aestheticreasons, the bracket may also vary in its design to accommodatedifferent mirror adjustment mechanisms. Today, some vehicles use amanual adjustment mechanism with a simple handle extending from themirror to the interior of the vehicle. Higher priced vehicles includeelectrically adjustable side rearview mirrors. These higher pricedvehicles use additional components to adjust the mirror. Depending uponwhich adjustment mechanism is desired in the vehicle, a separatemounting bracket would be necessary to accommodate the necessarycomponents of each adjustment mechanism. Again, the need for differentbrackets adds to the cost of the vehicle.

Also, the use of a mounting bracket makes the assembly of the mirror tothe vehicle difficult and time consuming. An assembly that wouldeliminate the use of a mounting bracket is highly desired.

There remains a need in the automotive industry for a side rearviewmirror assembly that is inexpensive to manufacture, yet easy to assembleand able to accommodate a variety of adjustment mechanisms. The presentinvention, as described below, fulfills each of these needs.

SUMMARY OF THE INVENTION

The subject invention is a mirror assembly having a mounting surfacewith an inner and outer side and an opening disposed therebetween. Themirror assembly also includes a case with a reflective mirror disposedwith the case. Positioned within the case is a guide mechanism having afirst aperture. A connector is positioned between the case and the innerside of the mounting surface and includes a second aperture. Finally,the mirror assembly also includes an adjustment mechanism.

A further understanding of the present invention will be had in view ofthe description of the drawings and detailed description of theinvention, when viewed in conjunction with the subjoined claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated asthe same becomes better understood by reference to the followingdetailed description when considered in connection with the accompanyingdrawings wherein:

FIG. 1 is a perspective view of a motor vehicle with a mirror assemblyof the subject invention;

FIG. 2 is an exploded view of the mirror assembly with a handleadjustment mechanism for manual adjustment of a mirror;

FIG. 3 is an exploded view of the mirror assembly with a harnessadjustment mechanism for electrical adjustment of the mirror;

FIG. 4A is an outer perspective view of a connector of the mirrorassembly;

FIG. 4B is an inner perspective view of the connector of the mirrorassembly;

FIG. 5 is a perspective view of an inner side of a mounting surface ofthe motor vehicle;

FIG. 6 is a perspective view of a guide mechanism of the mirror assemblyof the subject invention;

FIG. 7 is a perspective view of the handle adjustment mechanism of themirror assembly;

FIG. 8 is an inner perspective view of the handle adjustment mechanismextending through the connector and into the inner side of the mountingsurface of the motor vehicle;

FIG. 9 is a perspective view of the mirror assembly of the subjectinvention having a handle adjustment mechanism;

FIG. 10 is a perspective view of the mirror assembly of the subjectinvention having the harness adjustment mechanism;

FIG. 11 is a perspective view of the mirror assembly of the subjectinvention having the harness adjustment mechanism and the case moveable;and

FIG. 12 is a perspective view of the case of the mirror assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the Figures, wherein like numerals indicate like orcorresponding parts throughout the several views, a mirror assembly isgenerally shown at 10 in FIG. 1. The mirror assembly 10 is shownattached to the side of a motor vehicle generally shown at 12. Thesubject invention includes a mirror assembly 10 having three distinctembodiments—a handle mirror assembly 10, an electrically actuated mirrorassembly 10 and a moving case mirror assembly 10. All three embodimentshave the components described herein and shown in FIGS. 2 and 3.

The mirror assembly includes a case 14 having a generally rectangularshape and a reflective mirror 16 disposed within said case 14. The shapeof the reflective mirror 16 and case 14 of the present invention,however, can be of any shape. The reflective mirror 16 includes a backplate 18 that is connected to an adjustment mechanism 20. The adjustmentmechanism 20 has a first end 22 and a second end 24. The first end 22 ofthe adjustment mechanism 20 is attached to the back plate 18 of thereflective mirror 16 by conventional means commonly used in the art.

The case 14 also includes a guide mechanism 26. The guide mechanism 26has a first aperture 28. With the first end 22 of the adjustmentmechanism 20 connected to the back plate 18 of the reflective mirror 16,the second end 24 extends through this first aperture 28 of the guidemechanism 26 to an outer side of the case 14. The guide mechanism 26also includes wings 30 extending from each side of the first aperture28. An inner side 32 of the guide mechanism 26 faces the reflectivemirror 16 while an outer side 34 faces the motor vehicle. The outer side34 of the guide mechanism 26 includes a rib 36 and a knob 38. The rib 36is used to fixedly position the guide mechanism 26 to the case 14 in thehandle mirror assembly 10 and electrically actuated mirror assembly 10.The case 14 receives the rib 36 in a slot (not shown) to fixedlyposition the guide mechanism 26 in the case 14. The knob 38 is used inthe third embodiment of the moving case mirror assembly 10. The case 14in the moving case embodiment includes a plurality of grooves 40. Thesegrooves 40 receive the knob 38 of the guide mechanism 26 as the case 14rotates about the guide mechanism 26 and the adjustment mechanism 20.Rotating the case 14 permits the mirror assembly 10 to be folded inwardagainst the exterior side of the vehicle 12. Folding the mirror assembly10 inward reduces the overall width of the vehicle thereby assistingwhen shipping the vehicle 12 or parking the vehicle 12 in confinedspaces.

In order to attach the case 14 of the mirror assembly 10 to the vehicle12 a connector 42 is positioned between the case 14 and the vehicle 12.The connector 30 contains a second aperture 44 that also receives thesecond end 24 of the adjustment mechanism 20. The motor vehicle 12includes a mounting surface 46 having an inner side 48 and an outer side50. The mounting surface 46 is positioned on the side of the vehicle 12.The mounting surface 46 includes an opening 52. This opening 52 receivesthe connector 42 and the second end 24 of the adjustment mechanism 20.The connector 42 also includes a threaded hole 54 for receiving a screw56. The screw 56 is positioned at the inner side 48 of the mountingsurface 46 and threadably engages the threaded hole 54 to fixedly attachthe connector 42 to the vehicle 12. To further secure the connector 42to the vehicle 12, the connector 42 includes at lease one locking knob58 that engages an extension 60 in the mounting surface 46. Thepreferred embodiment illustrates the use of two locking knobs 58 thatengage two extensions 60 in the mounting surface 46, however, only onelocking knob 58 is required. The locking knob 58 requires that theconnector 42 be properly oriented for insertion through the opening 52of the mounting surface 46. Once inserted through the opening 52, theconnector 42 is rotated and then secured to the vehicle 12. In additionto the screw 56, the connector 42 also includes a lip 62 having alocking boss 64. The locking boss 64 is received in a locking embossment66 on the outer side 50 of the mounting surface 46. Therefore, toproperly connect the mirror assembly 10 to the vehicle 12, the connector42 is orientated to be inserted through the opening 52 of the mountingsurface 46 by passing the locking knob 58 through the extension 60 inthe mounting surface 46. Once properly inserted, the connector 42 isrotated and the locking boss 64 is received in the locking embossment66. The lip 62 is positioned flat against the outer side 50 of themounting surface 46. Finally, the screw 58 is threadably engaged withthe threaded hole 54 of the connector 42.

The adjustment mechanism 20 in all three embodiments extends through thefirst aperture 28 of the guide mechanism 26, the second aperture 44 ofthe connector 42 and the opening 52 in the mounting surface 46.Accordingly, the second end 24 of the adjustment mechanism 20 ispositioned on the inner side 48 of the mounting surface 46 and therebyinside the vehicle 12 and accessible to an operator.

In the first embodiment, the handle mirror assembly 10, the adjustmentmechanism 20 is a handle 68. The handle 68 has a generally tubular shapewith and angled extension 70 at the second end 24. The angled extension70 begins when then handle 68 reaches the inner side 48 of the mountingsurface 46. The extension 70 angles toward the operator of the vehicle12 for manual adjustment of the reflective surface 18. The handle 68also includes a locking mechanism 72 positioned at the inner side 48 ofthe mounting surface 46. The locking mechanism 72 is used to limit thevertical adjustment of the reflective surface 18. The locking mechanism72 is shown as a rectangular extension on the handle 68. The lockingmechanism 72 interferes with the connector 42 when moved to maximumupper or lower positions. The interference prevents any further verticaladjustment of the reflective surface 18. The width of the secondaperture 44 of the connector 42 limits the horizontal adjustment of thereflective surface 18 in the case 14. The horizontal stroke of thehandle 68 is limited when the handle 68 contacts a side surface of thesecond aperture 44 of the connector 42. To position the handle 68 withinthe case 14 the adjustment mechanism 20 includes a lip 74. Positionedbetween the lip 74 and the inner side 32 of the guide mechanism 26 is abiasing device 76. The biasing device 76, most commonly a spring, urgesthe guide mechanism 26 against the case 14 and the locking mechanism 72of the handle 68 against the connector 42, thereby properly positioningthe components of the mirror assembly 10. Furthermore, the portion ofthe handle 68 positioned in the first aperture 28 of the guide mechanism26 has a flattened surface 78 on one side of the tubular handle 68. Thisflattened surface 78 mates against a plane 80 within the first aperture28 of the guide mechanism 26. The mating of the flattened surface 78 andthe plane 80 prevents rotation of the handle 68 within the mirrorassembly 10. Again, this ensures that the components of the mirrorassembly 10 are properly positioned.

In the second embodiment, the electrically actuated mirror assembly 10,the adjustment mechanism 20 includes an electric motor 82 and a harness84. The electric motor 82 is positioned within the case 14 and isconnected to the back plate 18 of the reflective mirror 16. The electricmotor 82 actuates movement of the back plate 18 and reflective mirror 16within the case 14. The electric motor 82 receives power and controlsignals through electrical controls 86. The electrical controls 86 areconnected to the electric motor 82 and extend to inside the vehicle 12.The controls 86 are contained within the harness 86. The harness 84encapsulates the electronic controls 86 and extends from the electricmotor 82 to the inside of the vehicle 12. The harness 84, typically madeof plastic, also includes a plurality of strengthening ribs. Similarlyconfigured like the handle 68, the harness 82 also includes a lip 74 anda flattened surface 78. A biasing device 76 is positioned between thelip 74 and the inner side 32 of the guide mechanism 26. As with thehandle 68, the flattened surface 78 mates against the plane 80 in thefirst aperture 28 of the guide mechanism 26 to prevent rotation. Theelectronic controls 86 extend through the harness 84 and into thevehicle 12. The vehicle 12 will include a control mechanism (not shown)in which the operator commands movement of the reflective mirror 16within the case 14 and a signal is sent through the electrical controls86 and received by the electric motor 82.

The final embodiment, the moving case mirror assembly 10, only uses theadjustment mechanism 20 to properly position the components of themirror assembly 10. This embodiment only includes the harness 84. Theharness 84 is positioned as in the electrically actuated mirror assembly10. The biasing device 76 is positioned between the lip 74 and the innerside 32 of the guide mechanism 26 to properly position the components ofthe assembly 10. The harness 84 is left hollow. A plug (not shown)conceals the second end 24 of the harness 84 positioned inside thevehicle 12. The plug is strictly provided for aesthetic purposes. Themirror assembly 10 is adjusted by moving the case 14 about the guidemechanism 26. The knob 38 positioned on the outer side 34 of the guidemechanism 26 is received in one of a plurality of grooves 40 in the case14. The operator manually adjusts the mirror assembly 10. There are nocontrol mechanisms or handles. At a maximum position, the mirrorassembly 10 is flat against the side of the vehicle 12.

All three embodiments utilize the same components, thereby reducing themanufacturing costs for producing the vehicle 12. All assemblies 10 usethe same case 14, guide mechanism 26 and connector 42. The onlycomponent that varies is the type of adjustment mechanism 20 either thehandle 68, electric motor 82 with harness 84 or the harness 84 alone.The simplicity of alternating the adjustment mechanism 20 to accommodatevarious options with each vehicle 12 reduces the overall productioncosts and assembly efforts.

Those skilled in the art can now appreciate from the foregoingdescription that the broad teachings of the present invention can beimplemented in a variety of forms. Therefore, while this invention hasbeen described in connection with particular examples thereof, the truescope of the invention should not be so limited, since othermodifications will become apparent to the skilled practitioner upon astudy of the drawings, specification and following claims.

1. A mirror assembly comprising: a mounting surface having an inner sideand an outer side and an opening disposed therebetween; a case; areflective mirror disposed within said case; an adjustment mechanism; aguide mechanism positioned within said case and having a first aperture;and a connector having a second aperture and disposed between said caseand said inner side of said mounting surface.
 2. A mirror assembly asdescribed in claim 1 wherein said adjustment mechanism includes a firstend connected to said reflective mirror and a second end extendingthrough said first aperture of said guide mechanism, said secondaperture of said connector and said opening of said mounting surface. 3.A mirror assembly as described in claim 2 wherein said adjustmentmechanism is a handle for manual adjustment of said reflective mirrorwithin said case.
 4. A mirror assembly as described in claim 3 whereinsaid guide mechanism includes a rib for fixedly positioning said guidemechanism within said case.
 5. A mirror assembly as described in claim 3wherein said handle includes a locking mechanism for limiting verticaladjustment of said reflective mirror.
 6. A mirror assembly as describedin claim 2 wherein said adjustment mechanism is an electric motor and aharness encapsulating electrical controls for adjustment of saidreflective mirror within said case.
 7. A mirror assembly as described inclaim 6 wherein said guide mechanism includes a rib for fixedlypositioning said guide mechanism within said case.
 8. A mirror assemblyas described in claim 2 wherein said case is moveable about saidadjustment mechanism and said guide mechanism.
 9. A mirror assembly asdescribed in claim 8 wherein said case includes a plurality of groovesfor receiving a knob of said guide mechanism
 10. A mirror assembly asdescribed in claim 2 wherein said adjustment mechanism includes abiasing device for maintaining said adjustment mechanism and said guidemechanism properly positioned within said case.
 11. A mirror assembly asdescribed in claim 2 wherein said connector has an inner end and anouter end.
 12. A mirror assembly as described in claim 11 wherein saidconnector further includes a lip having a locking boss at said outerend.
 13. A mirror assembly as described in claim 12 wherein saidmounting surface has a locking embossment on said outer side forreceiving said locking boss of said connector.
 14. A mirror assembly asdescribed in claim 13 wherein said mounting surface further includes ascrew at said inner side for attaching said connector to said mountingsurface.
 15. A mirror assembly as described in claim 14 wherein saidinner end of said connector includes at least one locking knob
 16. Amirror assembly as described in claim 15 wherein said inner end of saidconnector further includes a threaded hole for receiving said screw ofsaid mounting surface.
 17. A mirror assembly as described in claim 16wherein said opening of said mounting surface includes at least oneextension for receiving said locking knob.
 18. A mirror assembly asdescribed in claim 2 wherein said first aperture of said guide mechanismincludes a plane to prevent rotation of said adjustment mechanism whilein said first aperture.
 19. A mirror assembly for use as a side rearviewmirror on a motor vehicle comprising: a mounting surface integral withsaid motor vehicle having an inner side and an outer side and an openingdisposed therebetween; a case having a reflective mirror disposedtherein; a guide mechanism having a first aperture and positioned withinsaid case; a connector having a second aperture and disposed betweensaid case and said inner side of said mounting surface; and anadjustment mechanism for changing the position of the reflective mirrorhaving a first end connected to said reflective mirror and a second endextending through said first aperture of said guide mechanism, saidsecond aperture of said connector and said opening of said mountingsurface.
 20. A mirror assembly as described in claim 19 wherein saidadjustment mechanism is a handle for manual adjustment of saidreflective mirror within said case.
 21. A mirror assembly as describedin claim 20 wherein said handle includes a locking mechanism forlimiting vertical adjustment of said reflective mirror.
 22. A mirrorassembly as described in claim 20 wherein said guide mechanism includesa rib for fixedly positioning said guide mechanism to said case.
 23. Amirror assembly as described in claim 19 wherein said adjustmentmechanism is an electric motor and a harness encapsulating electroniccontrols for controlling adjustment of said reflective mirror in saidcase.
 24. A mirror assembly as described in claim 23 wherein said guidemechanism includes a rib for fixedly positioning said guide mechanism tosaid case.
 25. A mirror assembly as described in claim 19 wherein saidcase is moveable around said adjustment mechanism and said guidemechanism.
 26. A mirror assembly as described in claim 25 wherein saidcase includes a plurality of grooves for receiving a knob on said guidemechanism.
 27. A mirror assembly as described in claim 19 wherein saidadjustment mechanism further includes a biasing device for properlypositioning said adjustment mechanism and said guide mechanism withinsaid case.
 28. A mirror assembly as described in claim 19 wherein saidconnector includes an inner end and an outer end, said inner endincluding a threaded hole and at least one knob and said outer endincluding a lip with a locking boss.
 29. A mirror assembly as describedin claim 28 wherein said inner side of said mounting surface includes ascrew for penetrating said threaded hole of said connector and attachingsaid connector to said mounting surface.
 30. A mirror assembly asdescribed in claim 29 wherein said outer side of said mounting surfaceincludes a locking embossment to receive said locking boss of saidconnector.
 31. A mirror assembly as described in claim 30 wherein saidopening of said mounting surface includes at least one extension forreceiving said knob of said connector.
 32. A mirror assembly asdescribed in claim 19 wherein said first aperture of said guidemechanism includes a plane for preventing rotation of said adjustmentmechanism within said first aperture.
 33. A mirror assembly for use on amotor vehicle comprising: a mounting surface having an inner side and anouter side and an opening disposed therebetween; a case; a reflectivemirror disposed within said case; a guide mechanism fixedly positionedwithin said case and having a first aperture with a plane; a connectorhaving a second aperture and positioned between said case and said innerside of said mounting surface; and a handle having a first end connectedto said reflective mirror and a second end extending through said firstaperture of said guide mechanism, said second aperture of said connectorand said opening of said mounting surface.
 34. A mirror assembly asdescribed in claim 33 wherein said handle includes a locking mechanismfor limiting vertical movement of said reflective mirror.
 35. A mirrorassembly as described in claim 33 wherein said handle further includesan angled extension at said second end.
 36. A mirror assembly asdescribed in claim 33 wherein said first end of said handle includes alip and a flat surface for mating with said plane of said guidemechanism.
 37. A mirror assembly as described in claim 33 including abiasing device for properly positioning said guide mechanism and saidhandle within said case.
 38. A mirror assembly for use on a motorvehicle comprising: a mounting surface having an inner side and an outerside and an opening disposed therebetween; a case; a reflective mirrordisposed within said case; a guide mechanism fixedly positioned withinsaid case and having a first aperture with a plane; a connector having asecond aperture and positioned between said case and said inner side ofsaid mounting surface; and a harness having a first end connected tosaid reflective mirror and a second end extending through said firstaperture of said guide mechanism, said second aperture of said connectorand said opening of said mounting surface.
 39. A mirror assembly asdescribed in claim 38 including an electric motor disposed in said casefor actuating movement of said reflective mirror via an electroniccontrol mechanism positioned inside the motor vehicle.
 40. A mirrorassembly as described in claim 38 wherein said harness is molded fromplastic and includes a plurality of strengthening ribs.
 41. A mirrorassembly as described in claim 38 including a biasing device forproperly positioning said guide mechanism and said harness within saidcase.
 42. A mirror assembly for use on a motor vehicle comprising: amounting surface having an inner side and an outer side and an openingdisposed therebetween; a case; a reflective mirror disposed within saidcase; a guide mechanism positioned within said case and having a knoband a first aperture with a plane; a connector having a second apertureand positioned between said case and said inner side of said mountingsurface; a harness having a first end connected to said reflectivemirror and a second end extending through said first aperture of saidguide mechanism, said second aperture of said connector and said openingof said mounting surface; and said case including a plurality of groovesfor receiving said knob of said guide mechanism, wherein said case ismoveable about said adjustment mechanism and said guide mechanism.